Nah, I'll probably stick with the Rookie title for now. I've been welding less than 3 years. I really consider myself to be at an apprentice level. Definately not pro or anywhere near. I've come a long way, but still have a lot to learn.

If anything, maybe I'll start another thread with welding projects or something like that in the title, and let others continue with the rookie thread.

Jim, the shelf/rack looks awesome! Let me know if you need more scrap.

And, yes - I am setting up to make panniers. This first set for Jim was more of a learning experience for me to tell me how much I need to charge. I still don't know because they are still at the powder coater, and I don't have a final price just yet.

I plan on making a basic set, and a GS styled set with exhaust cut-out. I do not plan on producing racks at this time. I will, however, make one-off racks for those willing to drop off their bike for a couple days. I will also make custom sizes to customer specs.

Also, I'm not going to sell my wares on this thread. I will start a thread in Vendors when I have my price point set, or I will simply sell bags on ebay as they are produced. My username is the same on ebay as it is here. I plan on offering good quality at good prices, and will only sell a set at a time so I don't get in over my head. Not to mention that I do enjoy my free time and don't plan on spending every second of it cranking out panniers.

If anyone is interested, please pm and I can get a little more specific. I just don't want to break any rules on this forum.

I will post up piccys of Jims racks/bags as soon as I can. I'm as anxious to see them as Jim is!

Kirk- so I was thinking maybe you might be able to make skidplates pretty easy with that new brake. Do you have a KLR to measure? You'd be horrified if you saw how much my skidplate resembles hammered shit (when it isn't covered in mud).

My problem with the current shape is that the front side seems to be shovel for mud and it just piles up in there. I figured a proper skidplate/engine guard would extend upward in the front to protect the motor from all the crap flinging off my front tire.

I have an '08 to measure to, so I'm not sure if the bolt pattern will be the same as yours.

My brake can only handle 12ga, and a proper skidplate should be 3/16" aluminum to provide any kind of protection.

One project I want to build this year will be a heavy-duty hydraulic press brake capable of bending 1/4" mild steel plate. If and when the time and money allows, of course. 3/16" aluminum is harder to bend than you would ever think.

Kirk- so I was thinking maybe you might be able to make skidplates pretty easy with that new brake. Do you have a KLR to measure? You'd be horrified if you saw how much my skidplate resembles hammered shit (when it isn't covered in mud).

My problem with the current shape is that the front side seems to be shovel for mud and it just piles up in there. I figured a proper skidplate/engine guard would extend upward in the front to protect the motor from all the crap flinging off my front tire.

I have an '08 to measure to, so I'm not sure if the bolt pattern will be the same as yours.

My brake can only handle 12ga, and a proper skidplate should be 3/16" aluminum to provide any kind of protection.

One project I want to build this year will be a heavy-duty hydraulic press brake capable of bending 1/4" mild steel plate. If and when the time and money allows, of course. 3/16" aluminum is harder to bend than you would ever think.

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I think that sort of skid plate should be a 2 piece, with the thick 3/16" only at the bottom and possibly 12ga up higher as is more of a mud protection, doubt you would be putting the weight of that bike anyplace other than the bottom when hitting a rock, log, animal or fellow rider.

These will be a nice upgrade from what's currently on my KLR, unless someone wants to claim them in the next day or two...

I will miter the corners after dinner and start TIGging the seams. I plan on having them and the lids to the powdercoater first thing in the morning. If I can slip them in Jim's batch, great! If not, it's not a biggie, and will give me an excuse to check Jim's status. Win-win!

I think that sort of skid plate should be a 2 piece, with the thick 3/16" only at the bottom and possibly 12ga up higher as is more of a mud protection, doubt you would be putting the weight of that bike anyplace other than the bottom when hitting a rock, log, animal or fellow rider.

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I think a thinner material is fine for more street use, but for hard-core, rock-busting offroading, 3/16" is what I personally would use for the whole bash plate.

I have 1/8" aluminum on my first KLR bash plate, but I mainly commute on mine. Plus, it's what I had on hand at the time. If I were to do it again, it would be 3/16"all over.

Yeah, a thicker bash plate is a necessity for me and my style. After I typed the message, I got to thinking that maybe I'll design and make my own. Not sure when I'll have time, but I figured I'm crafty enough to make a cardboard template, cut the pattern, score the bends, weld the backside of the bends, and connect the edges. We'll see.

Kirk- if you have the tools to do the thicker material before I get the time for DIY, then we'll talk.

Yeah, a thicker bash plate is a necessity for me and my style. After I typed the message, I got to thinking that maybe I'll design and make my own. Not sure when I'll have time, but I figured I'm crafty enough to make a cardboard template, cut the pattern, score the bends, weld the backside of the bends, and connect the edges. We'll see.

Kirk- if you have the tools to do the thicker material before I get the time for DIY, then we'll talk.

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MegaBash is all 3/16" al. plate. I can bend it now with my homemade brake.

I could make you one off your dimensions, but I'd be afraid of it not fitting w/o mocking up to an actual 1st gen KLR650. That would sucketh.